Vous êtes sur la page 1sur 26

IGNITION SYSTEM

CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION AND OPERATION
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . . 3
CAMSHAFT POSITION SENSOR . . . . . . . . . . . . . 4
CRANKSHAFT POSITION SENSOR
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CRANKSHAFT POSITION SENSOR
5.2L/5.9L V-8 ENGINES . . . . . . . . . . . . . . . . . . 3
DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENGINE COOLANT TEMPERATURE SENSOR . . . 4
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IGNITION SWITCH AND KEY
LOCK CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 4
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 2
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
POWERTRAIN CONTROL MODULE (PCM) . . . . 2
SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . . 3
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THROTTLE POSITION SENSOR . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING
AUTOMATIC SHUTDOWN (ASD)
RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CAMSHAFT POSITION SENSOR . . . . . . . . . . . . . 8
CRANKSHAFT POSITION SENSOR . . . . . . . . . . . 8
DISTRIBUTOR CAP . . . . . . . . . . . . . . . . . . . . . . . 7
DISTRIBUTOR ROTOR . . . . . . . . . . . . . . . . . . . . 7
ENGINE COOLANT TEMPERATURE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FAILURE TO START TEST . . . . . . . . . . . . . . . . . 6
IGNITION COIL TEST . . . . . . . . . . . . . . . . . . . . . 5
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . 7
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MAP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . . 9
SPARK PLUG CONDITIONS . . . . . . . . . . . . . . . . 9
TESTING FOR SPARK AT COIL . . . . . . . . . . . . . 5
REMOVAL AND INSTALLATION
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . 14
CAMSHAFT POSITION SENSOR . . . . . . . . . . . . 16
CRANKSHAFT POSITION SENSOR
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 15
CRANKSHAFT POSITION SENSOR
5.2L/5.9L ENGINES . . . . . . . . . . . . . . . . . . . . 15
DISTRIBUTOR4.0L ENGINE . . . . . . . . . . . . . 18
DISTRIBUTOR5.2L/5.9L ENGINES . . . . . . . . 16
ENGINE COOLANT TEMPERATURE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
IGNITION COIL4.0L ENGINE . . . . . . . . . . . . . 14
IGNITION COIL5.2L/5.9L ENGINES . . . . . . . 13
IGNITION SWITCH AND KEY CYLINDER . . . . . 21
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MANIFOLD ABSOLUTE PRESSURE
(MAP) SENSOR . . . . . . . . . . . . . . . . . . . . . . . 16
POWERTRAIN CONTROL MODULE (PCM) . . . 21
SHIFTER/IGNITION INTERLOCK . . . . . . . . . . . . 23
SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . 12
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . 12
THROTTLE POSITION SENSOR . . . . . . . . . . . . 16
SPECIFICATIONS
ENGINE FIRING ORDER4.0L 6-CYLINDER
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ENGINE FIRING ORDER5.2L/5.9L V-8
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
IGNITION COIL RESISTANCE . . . . . . . . . . . . . . 25
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . 24
SPARK PLUG CABLE RESISTANCE . . . . . . . . . 25
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . 25
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 25
VECI LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ZJ IGNITION SYSTEM 8D - 1
GENERAL INFORMATION
INTRODUCTION
Thi s group descri bes the i gni ti on systems for 5.2L/
5.9L V8 and 4.0L 6cyl i nder engi nes.
On Board Di agnosti cs i s descri bed i n Group 25,
Emi ssi on Control Systems.
Group 0, Lubri cati on and Mai ntenance, contai ns
general mai ntenance i nformati on (i n ti me or mi l eage
i nterval s) for i gni ti on rel ated i tems. The Owners
Manual al so contai ns mai ntenance i nformati on.
DESCRIPTION AND OPERATION
IGNITION SYSTEM
The i gni ti on systems used on 5.2L/5.9L V8 and
4.0L 6cyl i nder engi nes are basi cal l y i denti cal . Si mi -
l ari ti es and di fferences between the systems wi l l be
di scussed.
The i gni ti on system i s control l ed by the powertrai n
control modul e (PCM) on al l engi nes.
The i gni ti on system consi sts of:
Spark Pl ugs
I gni ti on Coi l
Secondary I gni ti on Cabl es
Di stri butor (contai ns rotor and camshaft posi ti on
sensor)
Powertrai n Control Modul e (PCM)
Crankshaft Posi ti on, Camshaft Posi ti on, Throt-
tl e Posi ti on and MAP Sensors
POWERTRAIN CONTROL MODULE (PCM)
The Powertrai n Control Modul e (PCM) i s l ocated
i n the engi ne compartment (Fi g. 1).
The i gni ti on system i s control l ed by the PCM.
NOTE: Base ignition timing by rotation of distribu-
tor is not adjustable.
The PCM opens and cl oses the i gni ti on coi l ground
ci rcui t to operate the i gni ti on coi l . Thi s i s done to
adjust i gni ti on ti mi ng, both i ni ti al (base) and
advance, and for changi ng engi ne operati ng condi -
ti ons.
The amount of el ectroni c spark advance provi ded
by the PCM i s determi ned by fi ve i nput factors:
engi ne cool ant temperature, engi ne rpm, i ntake man-
i fol d temperature, mani fol d absol ute pressure and
throttl e posi ti on.
DISTRIBUTOR
Al l 4.0L/5.2L/5.9L engi nes are equi pped wi th a
camshaft dri ven mechani cal di stri butor contai ni ng a
shaft dri ven di stri butor rotor. Al l di stri butors are
equi pped wi th an i nternal camshaft posi ti on (fuel
sync) sensor (Fi g. 2). Thi s sensor provi des fuel i njec-
ti on synchroni zati on and cyl i nder i denti fi cati on.
The di stri butor does not have bui l t i n centri fugal
or vacuum assi sted advance. Base i gni ti on ti mi ng
and al l ti mi ng advance i s control l ed by the power-
trai n control modul e (PCM). Because i gni ti on ti mi ng
i s control l ed by the PCM, base ignition timing is
not adjustable on any of these engines.
On the 4.0L 6cyl i nder engi ne, the di stri butor i s
l ocked i n pl ace by a fork wi th a sl ot l ocated on the
di stri butor housi ng base. The di stri butor hol ddown
cl amp bol t passes through thi s sl ot when i nstal l ed.
Because the di stri butor posi ti on i s l ocked when
i nstal l ed, i ts rotati onal posi ti on can not be changed.
Fig. 1 Powertrain Control Module (PCM) Location
Fig. 2 Distributor and Camshaft Position Sensor-
Typical (5.2L/5.9L Shown)
8D - 2 IGNITION SYSTEM ZJ
Do not attempt to modify the distributor hous-
ing to get distributor rotation. Distributor posi-
tion will have no effect on ignition timing. The
position of the distributor will determine fuel
synchronization only.
Al l 4.0L/5.2L/5.9L di stri butors contai n an i nternal
oi l seal that prevents oi l from enteri ng the di stri bu-
tor housi ng. The seal i s not servi ceabl e.
SPARK PLUGS
Al l engi nes use resi stor type spark pl ugs. Remove
the spark pl ugs and exami ne them for burned el ec-
trodes and foul ed, cracked or broken porcel ai n i nsu-
l ators. Keep pl ugs arranged i n the order i n whi ch
they were removed from the engi ne. A si ngl e pl ug
di spl ayi ng an abnormal condi ti on i ndi cates that a
probl em exi sts i n the correspondi ng cyl i nder. Repl ace
spark pl ugs at the i nterval s recommended i n Group
O, Lubri cati on and Mai ntenance
Spark pl ugs that have l ow mi l age may be cl eaned
and reused i f not otherwi se defecti ve, carbon or oi l
foul ed. Refer to the Spark Pl ug Condi ti on secti on of
thi s group.
SPARK PLUG CABLES
Spark pl ug cabl es are someti mes referred to as sec-
ondary i gni ti on wi res. These cabl es transfer el ectri cal
current from the i gni ti on coi l (s) and/or di stri butor, to
i ndi vi dual spark pl ugs at each cyl i nder. The resi sti ve
spark pl ug cabl es are of nonmetal l i c constructi on.
The cabl es provi de suppressi on of radi o frequency
emi ssi ons from the i gni ti on system.
IGNITION COIL
Battery vol tage i s suppl i ed to the i gni ti on coi l pos-
i ti ve termi nal from the ASD rel ay.
The Powertrai n Control Modul e (PCM) opens and
cl oses the i gni ti on coi l ground ci rcui t for i gni ti on coi l
operati on.
Base ignition timing is not adjustable on any
engine. By control l i ng the coi l ground ci rcui t, the
PCM i s abl e to set the base ti mi ng and adjust the
i gni ti on ti mi ng advance. Thi s i s done to meet chang-
i ng engi ne operati ng condi ti ons.
The i gni ti on coi l i s not oi l fi l l ed. The wi ndi ngs are
embedded i n an epoxy compound. Thi s provi des heat
and vi brati on resi stance that al l ows the i gni ti on coi l
to be mounted on the engi ne.
AUTOMATIC SHUTDOWN (ASD) RELAY
As one of i ts functi ons, the ASD rel ay wi l l suppl y
battery vol tage to the i gni ti on coi l . The ground ci r-
cui t for the ASD rel ay i s control l ed by the Powertrai n
Control Modul e (PCM). The PCM regul ates ASD
rel ay operati on by swi tchi ng the ground ci rcui t
on-and-off.
CRANKSHAFT POSITION SENSOR5. 2L/5. 9L V-8
ENGINES
Engi ne speed and crankshaft posi ti on are provi ded
through the crankshaft posi ti on sensor. The sensor
generates pul ses that are the i nput sent to the Pow-
ertrai n Control Modul e (PCM). The PCM i nterprets
the sensor i nput to determi ne the crankshaft posi -
ti on. The PCM then uses thi s posi ti on, al ong wi th
other i nputs, to determi ne i njector sequence and i gni -
ti on ti mi ng.
The sensor i s a hal l effect devi ce combi ned wi th an
i nternal magnet. I t i s al so sensi ti ve to steel wi thi n a
certai n di stance from i t.
On 5.2L/5.9L V-8 engi nes, the fl ywheel /dri ve pl ate
has 8 si ngl e notches, spaced every 45 degrees, at i ts
outer edge (Fi g. 3).
The notches cause a pul se to be generated when
they pass under the sensor. The pul ses are the i nput
to the PCM. For each engi ne revol uti on, there are 8
pul ses generated on V-8 engi nes.
The engi ne wi l l not operate i f the PCM does not
recei ve a crankshaft posi ti on sensor i nput.
CRANKSHAFT POSITION SENSOR4. 0L ENGINE
Engi ne speed and crankshaft posi ti on are provi ded
through the crankshaft posi ti on sensor. The sensor
generates pul ses that are the i nput sent to the pow-
ertrai n control modul e (PCM). The PCM i nterprets
the sensor i nput to determi ne the crankshaft posi -
ti on. The PCM then uses thi s posi ti on, al ong wi th
other i nputs, to determi ne i njector sequence and i gni -
ti on ti mi ng.
Fig. 3 Sensor Operation5.2L/5.9L Engines
ZJ IGNITION SYSTEM 8D - 3
DESCRIPTION AND OPERATION (Continued)
The sensor i s a hal l effect devi ce combi ned wi th an
i nternal magnet. I t i s al so sensi ti ve to steel wi thi n a
certai n di stance from i t.
On 4.0L 6-cyl i nder engi nes, the fl ywheel /dri ve
pl ate has 3 sets of four notches at i ts outer edge (Fi g.
4).
The notches cause a pul se to be generated when
they pass under the sensor. The pul ses are the i nput
to the PCM. For each engi ne revol uti on there are 3
sets of four pul ses generated.
The trai l i ng edge of the fourth notch, whi ch causes
the pul se, i s four degrees before top dead center
(TDC) of the correspondi ng pi ston.
The engi ne wi l l not operate i f the PCM does not
recei ve a crankshaft posi ti on sensor i nput.
CAMSHAFT POSITION SENSOR
The camshaft posi ti on sensor i s l ocated i n the di s-
tri butor on al l engi nes.
The sensor contai ns a hal l effect devi ce cal l ed a
sync si gnal generator to generate a fuel sync si gnal .
Thi s sync si gnal generator detects a rotati ng pul se
ri ng (shutter) on the di stri butor shaft. The pul se ri ng
rotates 180 degrees through the sync si gnal genera-
tor. I ts si gnal i s used i n conjuncti on wi th the crank-
shaft posi ti on sensor to di fferenti ate between fuel
i njecti on and spark events. I t i s al so used to synchro-
ni ze the fuel i njectors wi th thei r respecti ve cyl i nders.
When the l eadi ng edge of the pul se ri ng (shutter)
enters the sync si gnal generator, the fol l owi ng occurs:
The i nterrupti on of magneti c fi el d causes the vol tage
to swi tch hi gh resul ti ng i n a sync si gnal of approxi -
matel y 5 vol ts.
When the trai l i ng edge of the pul se ri ng (shutter)
l eaves the sync si gnal generator, the fol l owi ng occurs:
The change of the magneti c fi el d causes the sync si g-
nal vol tage to swi tch l ow to 0 vol ts.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
For an operati onal descri pti on, di agnosi s and
removal /i nstal l ati on procedures, refer to Group 14,
Fuel System.
ENGINE COOLANT TEMPERATURE SENSOR
For an operati onal descri pti on, di agnosi s and
removal /i nstal l ati on procedures, refer to Group 14,
Fuel System.
THROTTLE POSITION SENSOR
For an operati onal descri pti on, di agnosi s and
removal /i nstal l ati on procedures, refer to Group 14,
Fuel System.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
For an operati onal descri pti on, di agnosi s and
removal /i nstal l ati on procedures, refer to Group 14,
Fuel System.
IGNITION SWITCH AND KEY LOCK CYLINDER
The i gni ti on swi tch i s l ocated on the steeri ng col -
umn. The Key-I n-Swi tch i s l ocated i n the i gni ti on
swi tch modul e. For el ectri cal di agnosi s of the Key-I n-
Swi tch, refer to Group 8U, Chi me/Buzzer Warni ng
Systems. For removal /i nstal l ati on of ei ther the key
l ock cyl i nder or i gni ti on swi tch, refer to I gni ti on
Swi tch and Key Cyl i nder Removal /I nstal l ati on i n thi s
group.
On vehi cl es equi pped wi th an automati c transmi s-
si on, a cabl e connects an i nterl ock devi ce wi thi n the
steeri ng col umn assembl y to the transmi ssi on fl oor
shi ft l ever. Thi s i nterl ock devi ce i s used to l ock the
transmi ssi on shi fter i n the PARK posi ti on when the
key i s i n the LOCKED or ACCESSORY posi ti on. The
i nterl ock devi ce i s not servi ceabl e. I f repai r i s neces-
sary, the steeri ng col umn assembl y must be repl aced.
Refer to Group 19, Steeri ng for procedures. The
shi fter i nterl ock cabl e can be adjusted or repl aced.
Refer to Group 21, Transmi ssi ons for procedures.
DIAGNOSIS AND TESTING
AUTOMATIC SHUTDOWN (ASD) RELAY TEST
To perform a compl ete test of thi s rel ay and i ts ci r-
cui try, refer to the DRB scan tool . Al so refer to the
appropri ate Powertrai n Di agnosti cs Procedures man-
ual . To test the rel ay onl y, refer to Rel aysOpera-
ti on/Testi ng i n the Group 14, Fuel Systems secti on.
Fig. 4 Sensor Operation4.0L 6-Cyl. Engine
8D - 4 IGNITION SYSTEM ZJ
DESCRIPTION AND OPERATION (Continued)
TESTING FOR SPARK AT COIL
CAUTION: When disconnecting a high voltage
cable from a spark plug or from the distributor cap,
twist the rubber boot slightly (1/2 turn) to break it
loose (Fig. 5). Grasp the boot (not the cable) and
pull it off with a steady, even force.
(1) Di sconnect the i gni ti on coi l secondary cabl e
from center tower of the di stri butor cap. Hol d the
cabl e termi nal approxi matel y 12 mm (1/2 i n.) from a
good engi ne ground (Fi g. 6).
WARNING: BE VERY CAREFUL WHEN THE
ENGINE IS CRANKING. DO NOT PUT YOUR HANDS
NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT
WEAR LOOSE FITTING CLOTHING.
(2) Rotate (crank) the engi ne wi th the starter
motor and observe the cabl e termi nal for a steady
arc. I f steady arci ng does not occur, i nspect the sec-
ondary coi l cabl e. Refer to Spark Pl ug Cabl es i n thi s
group. Al so i nspect the di stri butor cap and rotor for
cracks or burn marks. Repai r as necessary. I f steady
arci ng occurs, connect i gni ti on coi l cabl e to the di s-
tri butor cap.
(3) Remove a cabl e from one spark pl ug.
(4) Usi ng i nsul ated pl i ers, hol d the cabl e termi nal
approxi matel y 12 mm (1/2 i n.) from the engi ne cyl i n-
der head or bl ock whi l e rotati ng the engi ne wi th the
starter motor. Observe the spark pl ug cabl e termi nal
for an arc. I f steady arci ng occurs, i t can be expected
that the i gni ti on secondary system i s operati ng cor-
rectl y. (If the ignition coil cable is removed for
this test, instead of a spark plug cable, the
spark intensity will be much higher). I f steady
arci ng occurs at the spark pl ug cabl es, but the engi ne
wi l l not start, connect the DRB scan tool . Refer to
the appropri ate Powertrai n Di agnosti c Procedures
servi ce manual .
IGNITION COIL TEST
To perform a compl ete test of the i gni ti on coi l and
i ts ci rcui try, refer to the DRB scan tool . Al so refer to
the appropri ate Powertrai n Di agnosti cs Procedures
manual . To test the coi l onl y, refer to the fol l owi ng:
The i gni ti on coi l (Fi g. 7) i s desi gned to operate
wi thout an external bal l ast resi stor.
Fig. 5 Cable Removal
Fig. 6 Checking for SparkTypical
Fig. 7 Ignition CoilTypical (5.2L/5.9L Shown)
ZJ IGNITION SYSTEM 8D - 5
DIAGNOSIS AND TESTING (Continued)
I nspect the i gni ti on coi l for arci ng. Test the coi l
accordi ng to coi l tester manufacturers i nstructi ons.
Test the coi l pri mary and secondary resi stance.
Repl ace any coi l that does not meet speci fi cati ons.
Refer to the I GNI TI ON COI L RESI STANCE chart.
I f the i gni ti on coi l i s bei ng repl aced, the secondary
spark pl ug cabl e must al so be checked. Repl ace cabl e
i f i t has been burned or damaged.
Arci ng at the tower wi l l carboni ze the cabl e boot,
whi ch i f i t i s connected to a new i gni ti on coi l , wi l l
cause the coi l to fai l .
I f the secondary coi l cabl e shows any si gns of dam-
age, i t shoul d be repl aced wi th a new cabl e and new
termi nal . Carbon tracki ng on the ol d cabl e can cause
arci ng and the fai l ure of a new i gni ti on coi l .
FAILURE TO START TEST
To prevent unnecessary di agnosti c ti me and wrong
test resul ts, the Testi ng For Spark At Coi l test
shoul d be performed pri or to thi s test.
WARNING: SET PARKING BRAKE OR BLOCK THE
DRIVE WHEELS BEFORE PROCEEDING WITH THIS
TEST.
(1) Unpl ug the i gni ti on coi l harness connector at
the coi l .
(2) Connect a set of smal l jumper wi res (18 gauge
or smal l er) between the di sconnected harness termi -
nal s and the i gni ti on coi l termi nal s. To determi ne
pol ari ty at connector and coi l , refer to the Wi ri ng
Di agrams secti on.
(3) Attach one l ead of a vol tmeter to the posi ti ve
(12 vol t) jumper wi re. Attach the negati ve si de of
vol tmeter to a good ground. Determi ne that suffi ci ent
battery vol tage (12.4 vol ts) i s present for the starti ng
and i gni ti on systems.
(4) Determi ne that suffi ci ent battery vol tage (12.4
vol ts) i s present for the starti ng and i gni ti on sys-
tems.
(5) Crank the engi ne for 5 seconds whi l e moni tor-
i ng the vol tage at the coi l posi ti ve termi nal :
I f the vol tage remai ns near zero duri ng the
enti re peri od of cranki ng, refer to On-Board Di agnos-
ti cs i n Group 14, Fuel Systems. Check the Power-
trai n Control Modul e (PCM) and auto shutdown
rel ay.
I f vol tage i s at or near battery vol tage and drops
to zero after 1-2 seconds of cranki ng, check the pow-
ertrai n control modul e ci rcui t. Refer to On-Board
Di agnosti cs i n Group 14, Fuel Systems.
I f vol tage remai ns at or near battery vol tage
duri ng the enti re 5 seconds, turn the key off. Remove
the three 32-way connectors (Fi g. 8) from the PCM.
Check 32-way connectors for any spread termi nal s or
corrosi on.
(6) Remove test l ead from the coi l posi ti ve termi -
nal . Connect an 18 gauge jumper wi re between the
battery posi ti ve termi nal and the coi l posi ti ve termi -
nal .
(7) Make the speci al jumper shown i n (Fi g. 9).
Usi ng the jumper, momentarily ground the i gni ti on
coi l dri ver ci rcui t at the PCM connector (cavi ty A-7).
For cavi ty/termi nal l ocati on of thi s ci rcui t, refer to
Group 8W, Wi ri ng. A spark shoul d be generated at
the coi l cabl e when the ground i s removed.
(8) I f spark i s generated, repl ace the PCM.
(9) I f spark i s not seen, use the speci al jumper to
ground the coi l negati ve termi nal di rectl y.
(10) I f spark i s produced, repai r wi ri ng harness for
an open condi ti on.
(11) I f spark i s not produced, repl ace the i gni ti on
coi l .
IGNITION COIL RESISTANCE
COIL MANUFACTURER
PRIMARY RESISTANCE 21-27C
(70-80F)
SECONDARY RESISTANCE
21-27C (70-80F)
Diamond 0.97 - 1.18 Ohms 11,300 - 15,300 Ohms
Toyodenso 0.95 - 1.20 Ohms 11,300 - 13,300 Ohms
Fig. 8 PCM and Three 32Way Connectors
8D - 6 IGNITION SYSTEM ZJ
DIAGNOSIS AND TESTING (Continued)
DISTRIBUTOR CAP
Remove the di stri butor cap and wi pe i t cl ean wi th
a dry l i nt free cl oth. Vi sual l y i nspect the cap for
cracks, carbon paths, broken towers or damaged
rotor button (Fi g. 10) or (Fi g. 11). Al so check for
whi te deposi ts on the i nsi de (caused by condensati on
enteri ng the cap through cracks). Repl ace any cap
that di spl ays charred or eroded termi nal s. The
machi ned surface of a termi nal end (faces toward
rotor) wi l l i ndi cate some evi dence of erosi on from
normal operati on. Exami ne the termi nal ends for evi -
dence of mechani cal i nterference wi th the rotor ti p.
DISTRIBUTOR ROTOR
Vi sual l y i nspect the rotor (Fi g. 12) for cracks, evi -
dence of corrosi on or the effects of arci ng on the
metal ti p. Al so check for evi dence of mechani cal
i nterference wi th the cap. Some charri ng i s normal
on the end of the metal ti p. The si l i cone-di el ectri c-
varni sh-compound appl i ed to the rotor ti p for radi o
i nterference noi se suppressi on, wi l l appear charred.
Thi s i s normal . Do not remove the charred com-
pound. Test the spri ng for i nsuffi ci ent tensi on.
Repl ace a rotor that di spl ays any of these adverse
condi ti ons.
IGNITION TIMING
NOTE: Base (initial) ignition timing is NOT adjust-
able on any 4.0L/5.2L/5.9L engine. Do not attempt to
adjust ignition timing by rotating the distributor.
NOTE: On 4.0L 6cylinder engines, do not attempt
to modify the slotted fork on the distributor housing
to get distributor rotation. Distributor position will
have no effect on ignition timing.
Al l i gni ti on ti mi ng functi ons are control l ed by the
powertrai n control modul e (PCM). For addi ti onal
i nformati on, refer to the appropri ate Powertrai n
Di agnosti cs Procedures servi ce manual for operati on
of the DRB Scan Tool .
Fig. 9 Special Jumper Ground-to-Coil Negative
Terminal
Fig. 10 Cap InspectionExternalTypical
Fig. 11 Cap InspectionInternalTypical
Fig. 12 Rotor InspectionTypical
ZJ IGNITION SYSTEM 8D - 7
DIAGNOSIS AND TESTING (Continued)
MAP SENSOR
For an operati onal descri pti on, di agnosi s or remov-
al / i nstal l ati on procedures, refer to Group 14, Fuel
Systems.
CRANKSHAFT POSITION SENSOR
To perform a compl ete test of thi s sensor and i ts
ci rcui try, refer to the DRB scan tool . Al so refer to the
appropri ate Powertrai n Di agnosti cs Procedures man-
ual .
CAMSHAFT POSITION SENSOR
The camshaft posi ti on sensor i s l ocated i n the di s-
tri butor (Fi g. 13) on al l engi nes.
To perform a compl ete test of thi s sensor and i ts
ci rcui try, refer to the appropri ate Powertrai n Di ag-
nosti cs Procedures servi ce manual . To test the sensor
onl y, refer to the fol l owi ng:
For this test, an analog (non-digital) voltme-
ter is needed. Do not remove the di stri butor connec-
tor from the di stri butor. Usi ng smal l paper cl i ps,
i nsert them i nto the backsi de of the di stri butor wi re
harness connector to make contact wi th the termi -
nal s. Be sure that the connector i s not damaged
when i nserti ng the paper cl i ps. Attach vol tmeter
l eads to these paper cl i ps.
(1) Connect the posi ti ve (+) vol tmeter l ead i nto the
sensor output wi re. Thi s i s at done the di stri butor
wi re harness connector. For wi re i denti fi cati on, refer
to Group 8W, Wi ri ng Di agrams.
(2) Connect the negati ve (-) vol tmeter l ead i nto the
ground wi re. For wi re i denti fi cati on, refer to Group
8W, Wi ri ng Di agrams.
(3) Set the vol tmeter to the 15 Vol t DC scal e.
(4) 5.2L/5.9L Engines: Remove di stri butor cap
from di stri butor (two screws). Rotate (crank) the
engi ne unti l the di stri butor rotor i s poi nted towards
the rear of vehi cl e. The movabl e pul se ri ng shoul d
now be wi thi n the sensor pi ckup.
(5) 4.0L Engine: Remove di stri butor cap from di s-
tri butor (two screws). Rotate (crank) the engi ne unti l
the di stri butor rotor i s poi nted to approxi matel y the
11 ocl ock posi ti on. The movabl e pul se ri ng shoul d
now be wi thi n the sensor pi ckup.
(6) Turn i gni ti on key to ON posi ti on. Vol tmeter
shoul d read approxi matel y 5.0 vol ts.
(7) I f vol tage i s not present, check the vol tmeter
l eads for a good connecti on.
(8) I f vol tage i s sti l l not present, check for vol tage
at the suppl y wi re. For wi re i denti fi cati on, refer to
Group 8W, Wi ri ng Di agrams.
(9) I f 5 vol ts i s not present at suppl y wi re, check
for vol tage at PCM 32-way connector (cavi ty A-17).
Refer to Group 8W, Wi ri ng for l ocati on of connector/
termi nal . Leave the PCM connector connected for
thi s test.
(10) I f vol tage i s sti l l not present, perform vehi cl e
test usi ng the DRB scan tool .
(11) I f vol tage i s present at cavi ty A-17, but not at
the suppl y wi re:
(a) Check conti nui ty between the suppl y wi re.
Thi s i s checked between the di stri butor connector
and cavi ty A-17 at the PCM. I f conti nui ty i s not
present, repai r the harness as necessary.
(b) Check for conti nui ty between the camshaft
posi ti on sensor output wi re and cavi ty A-18 at the
PCM. I f conti nui ty i s not present, repai r the har-
ness as necessary.
(c) Check for conti nui ty between the ground ci r-
cui t wi re at the di stri butor connector and ground.
I f conti nui ty i s not present, repai r the harness as
necessary.
(12) Whi l e observi ng the vol tmeter, crank the
engi ne wi th i gni ti on swi tch. The vol tmeter needl e
shoul d fl uctuate between 0 and 5 vol ts whi l e the
engi ne i s cranki ng. Thi s veri fi es that the camshaft
posi ti on sensor i n the di stri butor i s operati ng prop-
erl y and a sync pul se si gnal i s bei ng generated.
I f sync pul se si gnal i s not present, repl acement of
the camshaft posi ti on sensor i s necessary
ENGINE COOLANT TEMPERATURE SENSOR
For an operati onal descri pti on, di agnosi s and
removal /i nstal l ati on procedures, refer to Group 14,
Fuel System.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
For an operati onal descri pti on, di agnosi s and
removal /i nstal l ati on procedures, refer to Group 14,
Fuel System.
Fig. 13 Camshaft Position SensorTypical
(5.2L/5.9L Distributor Shown)
8D - 8 IGNITION SYSTEM ZJ
DIAGNOSIS AND TESTING (Continued)
SPARK PLUG CABLES
Check the spark pl ug cabl e connecti ons for good
contact at the coi l (s), di stri butor cap towers, and
spark pl ugs. Termi nal s shoul d be ful l y seated. The
i nsul ators shoul d be i n good condi ti on and shoul d fi t
ti ghtl y on the coi l , di stri butor and spark pl ugs. Spark
pl ug cabl es wi th i nsul ators that are cracked or torn
must be repl aced.
Cl ean hi gh vol tage i gni ti on cabl es wi th a cl oth
moi stened wi th a non-fl ammabl e sol vent. Wi pe the
cabl es dry. Check for bri ttl e or cracked i nsul ati on.
On 5.2L/5.9L V-8 engi nes, spark pl ug cabl e heat
shi el ds are pressed i nto the cyl i nder head to sur-
round each spark pl ug cabl e boot and spark pl ug
(Fi g. 14). These shi el ds protect the spark pl ug boots
from damage (due to i ntense engi ne heat generated
by the exhaust mani fol ds) and shoul d not be
removed. After the spark pl ug cabl e has been
i nstal l ed, the l i p of the cabl e boot shoul d have a
smal l ai r gap to the top of the heat shi el d (Fi g. 14).
TESTING
When testi ng secondary cabl es for damage wi th an
osci l l oscope, fol l ow the i nstructi ons of the equi pment
manufacturer.
I f an osci l l oscope i s not avai l abl e, spark pl ug cabl es
may be tested as fol l ows:
CAUTION: Do not leave any one spark plug cable
disconnected for longer than necessary during test-
ing. This may cause possible heat damage to the
catalytic converter. Total test time must not exceed
ten minutes.
Wi th the engi ne runni ng, remove spark pl ug cabl e
from spark pl ug (one at a ti me) and hol d next to a
good engi ne ground. I f the cabl e and spark pl ug are
i n good condi ti on, the engi ne rpm shoul d drop and
the engi ne wi l l run poorl y. I f engi ne rpm does not
drop, the cabl e and/or spark pl ug may not be operat-
i ng properl y and shoul d be repl aced. Al so check
engi ne cyl i nder compressi on.
Wi th the engi ne not runni ng, connect one end of a
test probe to a good ground. Start the engi ne and run
the other end of the test probe al ong the enti re
l ength of al l spark pl ug cabl es. I f cabl es are cracked
or punctured, there wi l l be a noti ceabl e spark jump
from the damaged area to the test probe. The cabl e
runni ng from the i gni ti on coi l to the di stri butor cap
can be checked i n the same manner. Cracked, dam-
aged or faul ty cabl es shoul d be repl aced wi th resi s-
tance type cabl e. Thi s can be i denti fi ed by the words
ELECTRONI C SUPPRESSI ON pri nted on the cabl e
jacket.
Use an ohmmeter to test for open ci rcui ts, exces-
si ve resi stance or l oose termi nal s. I f equi pped,
remove the di stri butor cap from the di stri butor. Do
not remove cables from cap. Remove cabl e from
spark pl ug. Connect ohmmeter to spark pl ug termi -
nal end of cabl e and to correspondi ng el ectrode i n
di stri butor cap. Resi stance shoul d be 250 to 1000
Ohms per i nch of cabl e. I f not, remove cabl e from di s-
tri butor cap tower and connect ohmmeter to the ter-
mi nal ends of cabl e. I f resi stance i s not wi thi n
speci fi cati ons as found i n the SPARK PLUG CABLE
RESI STANCE chart, repl ace the cabl e. Test al l spark
pl ug cabl es i n thi s manner.
To test i gni ti on coi l -to-di stri butor cap cabl e, do not
remove the cabl e from the cap. Connect ohmmeter to
rotor button (center contact) of di stri butor cap and
termi nal at i gni ti on coi l end of cabl e. I f resi stance i s
not wi thi n speci fi cati ons as found i n the Spark Pl ug
Cabl e Resi stance chart, remove the cabl e from the
di stri butor cap. Connect the ohmmeter to the termi -
nal ends of the cabl e. I f resi stance i s not wi thi n spec-
i fi cati ons as found i n the Spark Pl ug Cabl e
Resi stance chart, repl ace the cabl e. I nspect the i gni -
ti on coi l tower for cracks, burns or corrosi on.
SPARK PLUG CONDITIONS
NORMAL OPERATING
The few deposi ts present on the spark pl ug wi l l
probabl y be l i ght tan or sl i ghtl y gray i n col or. Thi s i s
evi dent wi th most grades of commerci al gasol i ne
(Fi g. 15). There wi l l not be evi dence of el ectrode
burni ng. Gap growth wi l l not average more than
approxi matel y 0.025 mm (.001 i n) per 1600 km (1000
Fig. 14 Heat Shields5.2L/5.9L V-8 Engines
SPARK PLUG CABLE RESISTANCE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per
Inch
3000 Ohms Per Foot 12,000 Ohms
Per Foot
ZJ IGNITION SYSTEM 8D - 9
DIAGNOSIS AND TESTING (Continued)
mi l es) of operati on. Spark pl ugs that have normal
wear can usual l y be cl eaned, have the el ectrodes
fi l ed, have the gap set and then be i nstal l ed.
Some fuel refi ners i n several areas of the Uni ted
States have i ntroduced a manganese addi ti ve (MMT)
for unl eaded fuel . Duri ng combusti on, fuel wi th MMT
causes the enti re ti p of the spark pl ug to be coated
wi th a rust col ored deposi t. Thi s rust col or can be
mi sdi agnosed as bei ng caused by cool ant i n the com-
busti on chamber. Spark pl ug performance i s not
affected by MMT deposi ts.
COLD FOULING/CARBON FOULING
Col d foul i ng i s someti mes referred to as carbon
foul i ng. The deposi ts that cause col d foul i ng are basi -
cal l y carbon (Fi g. 15). A dry, bl ack deposi t on one or
two pl ugs i n a set may be caused by sti cki ng val ves
or defecti ve spark pl ug cabl es. Col d (carbon) foul i ng
of the enti re set of spark pl ugs may be caused by a
cl ogged ai r cl eaner el ement or repeated short operat-
i ng ti mes (short tri ps).
WET FOULING OR GAS FOULING
A spark pl ug coated wi th excessi ve wet fuel or oi l
i s wet foul ed. I n ol der engi nes, worn pi ston ri ngs,
l eaki ng val ve gui de seal s or excessi ve cyl i nder wear
can cause wet foul i ng. I n new or recentl y overhaul ed
engi nes, wet foul i ng may occur before break-i n (nor-
mal oi l control ) i s achi eved. Thi s condi ti on can usu-
al l y be resol ved by cl eani ng and rei nstal l i ng the
foul ed pl ugs.
OIL OR ASH ENCRUSTED
I f one or more spark pl ugs are oi l or oi l ash
encrusted (Fi g. 16), eval uate engi ne condi ti on for the
cause of oi l entry i nto that parti cul ar combusti on
chamber.
ELECTRODE GAP BRIDGING
El ectrode gap bri dgi ng may be traced to l oose
deposi ts i n the combusti on chamber. These deposi ts
accumul ate on the spark pl ugs duri ng conti nuous
stop-and-go dri vi ng. When the engi ne i s suddenl y
subjected to a hi gh torque l oad, deposi ts parti al l y l i q-
uefy and bri dge the gap between el ectrodes (Fi g. 17).
Thi s short ci rcui ts the el ectrodes. Spark pl ugs wi th
el ectrode gap bri dgi ng can be cl eaned usi ng standard
procedures.
SCAVENGER DEPOSITS
Fuel scavenger deposi ts may be ei ther whi te or yel -
l ow (Fi g. 18). They may appear to be harmful , but
thi s i s a normal condi ti on caused by chemi cal addi -
ti ves i n certai n fuel s. These addi ti ves are desi gned to
Fig. 15 Normal Operation and Cold (Carbon) Fouling
Fig. 16 Oil or Ash Encrusted
Fig. 17 Electrode Gap Bridging
8D - 10 IGNITION SYSTEM ZJ
DIAGNOSIS AND TESTING (Continued)
change the chemi cal nature of deposi ts and decrease
spark pl ug mi sfi re tendenci es. Noti ce that accumul a-
ti on on the ground el ectrode and shel l area may be
heavy, but the deposi ts are easi l y removed. Spark
pl ugs wi th scavenger deposi ts can be consi dered nor-
mal i n condi ti on and can be cl eaned usi ng standard
procedures.
CHIPPED ELECTRODE INSULATOR
A chi pped el ectrode i nsul ator usual l y resul ts from
bendi ng the center el ectrode whi l e adjusti ng the
spark pl ug el ectrode gap. Under certai n condi ti ons,
severe detonati on can al so separate the i nsul ator
from the center el ectrode (Fi g. 19). Spark pl ugs wi th
thi s condi ti on must be repl aced.
PREIGNITION DAMAGE
Prei gni ti on damage i s usual l y caused by excessi ve
combusti on chamber temperature. The center el ec-
trode di ssol ves fi rst and the ground el ectrode di s-
sol ves somewhat l atter (Fi g. 20). I nsul ators appear
rel ati vel y deposi t free. Determi ne i f the spark pl ug
has the correct heat range rati ng for the engi ne.
Determi ne i f i gni ti on ti mi ng i s over advanced or i f
other operati ng condi ti ons are causi ng engi ne over-
heati ng. (The heat range rati ng refers to the operat-
i ng temperature of a parti cul ar type spark pl ug.
Spark pl ugs are desi gned to operate wi thi n speci fi c
temperature ranges. Thi s depends upon the thi ck-
ness and l ength of the center el ectrodes porcel ai n
i nsul ator.)
SPARK PLUG OVERHEATING
Overheati ng i s i ndi cated by a whi te or gray center
el ectrode i nsul ator that al so appears bl i stered (Fi g.
21). The i ncrease i n el ectrode gap wi l l be consi der-
abl y i n excess of 0.001 i nch per 1000 mi l es of opera-
ti on. Thi s suggests that a pl ug wi th a cool er heat
range rati ng shoul d be used. Over advanced i gni ti on
ti mi ng, detonati on and cool i ng system mal functi ons
can al so cause spark pl ug overheati ng.
Fig. 18 Scavenger Deposits
Fig. 19 Chipped Electrode Insulator
Fig. 20 Preignition Damage
Fig. 21 Spark Plug Overheating
ZJ IGNITION SYSTEM 8D - 11
DIAGNOSIS AND TESTING (Continued)
REMOVAL AND INSTALLATION
SPARK PLUG CABLES
CAUTION: When disconnecting a high voltage
cable from a spark plug or from the distributor cap,
twist the rubber boot slightly (1/2 turn) to break it
loose (Fig. 22). Grasp the boot (not the cable) and
pull it off with a steady, even force.
I nstal l cabl es i nto the proper engi ne cyl i nder fi ri ng
order (Fi g. 23) or (Fi g. 24).
When repl aci ng the spark pl ug and coi l cabl es,
route the cabl es correctl y and secure i n the proper
retai ners. Fai l ure to route the cabl es properl y can
cause the radi o to reproduce i gni ti on noi se. I t coul d
al so cause cross i gni ti on of the pl ugs or short ci rcui t
the cabl es to ground.
When i nstal l i ng new cabl es, make sure a posi ti ve
connecti on i s made. A snap shoul d be fel t when a
good connecti on i s made between the pl ug cabl e and
the di stri butor cap tower.
SPARK PLUGS
On 5.2L/5.9L V-8 engi nes, spark pl ug cabl e heat
shi el ds are pressed i nto the cyl i nder head to sur-
round each cabl e boot and spark pl ug (Fi g. 25).
I f removal of the heat shi el d(s) i s necessary,
remove the spark pl ug cabl e and compress the si des
of shi el d for removal . Each shi el d i s sl otted to al l ow
for compressi on and removal . To i nstal l the shi el ds,
al i gn shi el d to machi ned openi ng i n cyl i nder head
and tap i nto pl ace wi th a bl ock of wood.
PLUG REMOVAL
(1) Al ways remove spark pl ug or i gni ti on coi l
cabl es by graspi ng at the cabl e boot (Fi g. 22). Turn
the cabl e boot 1/2 turn and pul l strai ght back i n a
steady moti on. Never pul l di rectl y on the cabl e.
I nternal damage to cabl e wi l l resul t.
Fig. 22 Cable Removal
Fig. 23 Engine Firing Order4.0L 6Cyl. Engine
Fig. 24 Engine Firing Order5.2L/5.9L V-8 Engines
Fig. 25 Heat Shields5.2L/5.9L Engines
8D - 12 IGNITION SYSTEM ZJ
(2) Pri or to removi ng the spark pl ug, spray com-
pressed ai r around the spark pl ug hol e and the area
around the spark pl ug. Thi s wi l l hel p prevent forei gn
materi al from enteri ng the combusti on chamber.
(3) Remove the spark pl ug usi ng a qual i ty socket
wi th a rubber or foam i nsert.
(4) I nspect the spark pl ug condi ti on. Refer to
Spark Pl ug Condi ti on i n the Di agnosti cs and Testi ng
secti on of thi s group.
PLUG CLEANING
The pl ugs may be cl eaned usi ng commerci al l y
avai l abl e spark pl ug cl eani ng equi pment. After cl ean-
i ng, fi l e the center el ectrode fl at wi th a smal l poi nt
fi l e or jewel ers fi l e before adjusti ng gap.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.
PLUG GAP ADJ USTMENT
Check the spark pl ug gap wi th a gap gauge tool . I f
the gap i s not correct, adjust i t by bendi ng the
ground el ectrode (Fi g. 26). Never attempt to adjust
the gap by bending the center electrode.
SPARK PLUG GAP
4.0L 6Cyl. Engine: .89 mm (.035 i n).
5.2/5.9L V-8 Engines: 1.01 mm (.040 i n).
PLUG INSTALLATION
Speci al care shoul d be taken when i nstal l i ng spark
pl ugs i nto the cyl i nder head spark pl ug wel l s. Be
sure the pl ugs do not drop i nto the pl ug wel l s as el ec-
trodes can be damaged.
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on resul ti ng i n a
change i n the spark pl ug gap or a cracked porcel ai n
i nsul ator.
When repl aci ng the spark pl ug and i gni ti on coi l
cabl es, route the cabl es correctl y and secure them i n
the appropri ate retai ners. Fai l ure to route the cabl es
properl y can cause the radi o to reproduce i gni ti on
noi se. I t coul d cause cross i gni ti on of the spark pl ugs
or short ci rcui t the cabl es to ground.
(1) Start the spark pl ug i nto the cyl i nder head by
hand to avoi d cross threadi ng.
(2) Ti ghten spark pl ugs to 35-41 Nm (26-30 ft.
l bs.) torque.
(3) I nstal l spark pl ug cabl es over spark pl ugs.
IGNITION COIL5. 2L/5. 9L ENGINES
The i gni ti on coi l i s an epoxy fi l l ed type. I f the coi l
i s repl aced, i t must be repl aced wi th the same type.
REMOVAL
The coi l i s mounted to a bracket that i s bol ted to
the front of the ri ght engi ne cyl i nder head (Fi g. 27).
Thi s bracket i s mounted on top of the automati c bel t
tensi oner bracket usi ng common bol ts.
(1) Di sconnect the pri mary wi ri ng from the i gni -
ti on coi l .
(2) Di sconnect the secondary spark pl ug cabl e from
the i gni ti on coi l .
Fig. 26 Setting Spark Plug GapTypical
Fig. 27 Ignition Coil5.2L/5.9L V-8 Engines
ZJ IGNITION SYSTEM 8D - 13
REMOVAL AND INSTALLATION (Continued)
WARNING: DO NOT REMOVE THE COIL MOUNT-
ING BRACKET-TO-CYLINDER HEAD MOUNTING
BOLTS. THE COIL MOUNTING BRACKET IS UNDER
ACCESSORY DRIVE BELT TENSION. IF THIS
BRACKET IS TO BE REMOVED FOR ANY REASON,
ALL BELT TENSION MUST FIRST BE RELIEVED.
REFER TO THE BELT SECTION OF GROUP 7,
COOLING SYSTEM.
(3) Remove i gni ti on coi l from coi l mounti ng
bracket (two bol ts).
INSTALLATION
(1) I nstal l the i gni ti on coi l to coi l bracket. I f nuts
and bol ts are used to secure coi l to coi l bracket,
ti ghten to 11 Nm (100 i n. l bs.) torque. I f the coi l
mounti ng bracket has been tapped for coi l mounti ng
bol ts, ti ghten bol ts to 5 Nm (50 i n. l bs.) torque.
(2) Connect al l wi ri ng to i gni ti on coi l .
IGNITION COIL4. 0L ENGINE
The i gni ti on coi l i s an epoxy fi l l ed type. I f the coi l
i s repl aced, i t must be repl aced wi th the same type.
REMOVAL
The i gni ti on coi l i s mounted to a bracket on the
si de of the engi ne to the front of the di stri butor (Fi g.
28).
(1) Di sconnect the i gni ti on coi l secondary cabl e
from i gni ti on coi l (Fi g. 28).
(2) Di sconnect engi ne harness connector from i gni -
ti on coi l .
(3) Remove i gni ti on coi l mounti ng bol ts (nuts may
al so be used on back si de of bracket).
(4) Remove coi l .
INSTALLATION
(1) I nstal l i gni ti on coi l to bracket. I f nut and bol ts
are used to secure coi l to coi l bracket, ti ghten to 11
Nm (100 i n. l bs.) torque. I f bol ts are used, ti ghten
bol ts to 5 Nm (50 i n. l bs.) torque.
(2) Connect engi ne harness connector to coi l .
(3) Connect i gni ti on coi l cabl e to i gni ti on coi l .
AUTOMATIC SHUTDOWN (ASD) RELAY
The Automati c Shutdown (ASD) rel ay i s l ocated i n
the Power Di stri buti on Center (PDC). The PDC i s
l ocated i n the engi ne compartment (Fi g. 29). Refer to
l abel on PDC cover for rel ay l ocati on.
REMOVAL
(1) Remove PDC cover.
(2) Remove rel ay by l i fti ng strai ght up.
INSTALLATION
(1) Check condi ti on of rel ay termi nal s at PDC for
corrosi on or damage. Al so check the hei ghts of rel ay
termi nal pi ns at PDC. Pi n hei ght shoul d be same for
al l pi ns. Repai r as necessary before i nstal l i ng rel ay.
(2) Push rel ay i nto connector.
(3) I nstal l rel ay cover.
Fig. 28 Ignition Coil4.0L Engine
Fig. 29 Power Distribution Center
8D - 14 IGNITION SYSTEM ZJ
REMOVAL AND INSTALLATION (Continued)
CRANKSHAFT POSITION SENSOR5. 2L/5. 9L
ENGINES
REMOVAL
The sensor i s bol ted to the top of the cyl i nder bl ock
near the rear of ri ght cyl i nder head (Fi g. 30).
(1) Di sconnect crankshaft posi ti on sensor pi gtai l
harness (3way connector) from mai n wi ri ng harness.
(2) Remove two sensor (recessed hex head) mount-
i ng bol ts (Fi g. 30).
(3) Remove sensor from engi ne.
INSTALLATION
(1) Posi ti on crankshaft posi ti on sensor to engi ne.
(2) I nstal l mounti ng bol ts and ti ghten to 8 Nm (70
i n. l bs.) torque.
(3) Connect mai n harness el ectri cal connector to
sensor.
CRANKSHAFT POSITION SENSOR4. 0L ENGINE
The crankshaft posi ti on sensor i s mounted to the
transmi ssi on bel l housi ng at the l eft/rear si de of the
engi ne bl ock (Fi g. 31). The sensor is adjustable and
i s attached wi th one bol t. A wi re shi el d/router i s
attached to the sensor (Fi g. 31).
REMOVAL
(1) Di sconnect sensor pi gtai l harness (3way con-
nector) from mai n engi ne wi ri ng harness. Thi s con-
necti on i s made near rear of di stri butor.
(2) Remove sensor mounti ng bol t.
(3) Remove wi re shi el d and sensor.
INSTALLATION
4.0L engines with automatic transmission:
New repl acement sensors wi l l be equi pped wi th a
paper spacer gl ued to bottom of sensor. I f i nstal l i ng
(returni ng) a used sensor to vehi cl e, a new paper
spacer must be i nstal l ed to bottom of sensor. Thi s
spacer wi l l be ground off the fi rst ti me engi ne i s
started. I f spacer i s not used, sensor wi l l be broken
the fi rst ti me engi ne i s started.
(1) New Sensors: Be sure paper spacer i s i nstal l ed
to bottom of sensor. I f not, obtai n spacer
PN05252229.
(2) Used Sensors: Cl ean bottom of sensor and
i nstal l spacer PN05252229.
(3) I nstal l sensor i nto transmi ssi on bel l housi ng
hol e.
(4) Posi ti on sensor wi re shi el d to sensor (Fi g. 31).
(5) Push sensor agai nst fl ywheel /dri ve pl ate. Wi th
sensor pushed agai nst fl ywheel /dri ve pl ate, ti ghten
mounti ng bol t to 7 Nm (60 i n. l bs.) torque.
Fig. 30 Crankshaft Position Sensor5.2L/5.9L
Engines
Fig. 31 Crankshaft Position Sensor4.0L 6-Cylinder
Engine
ZJ IGNITION SYSTEM 8D - 15
REMOVAL AND INSTALLATION (Continued)
(6) Route sensor wi ri ng harness i nto wi re shi el d.
(7) Connect sensor pi gtai l harness el ectri cal con-
nector to mai n wi ri ng harness.
CAMSHAFT POSITION SENSOR
The camshaft posi ti on sensor i s l ocated i n the di s-
tri butor on al l 4.0L 6cyl i nder and 5.2L/5.9L V-8
engi nes (Fi g. 32).
REMOVAL
Di stri butor removal i s not necessary to remove
camshaft posi ti on sensor.
(1) 5.2L/5.9L Engi nes: Remove ai r cl eaner tube at
throttl e body.
(2) Di sconnect negati ve cabl e from battery.
(3) Remove di stri butor cap from di stri butor (two
screws).
(4) Di sconnect camshaft posi ti on sensor wi ri ng
harness from mai n engi ne wi ri ng harness.
(5) Remove di stri butor rotor from di stri butor shaft.
(6) Li ft the camshaft posi ti on sensor assembl y
from the di stri butor housi ng (Fi g. 32).
INSTALLATION
(1) I nstal l camshaft posi ti on sensor to di stri butor.
Al i gn sensor i nto notch on di stri butor housi ng.
(2) Connect wi ri ng harness.
(3) I nstal l rotor.
(4) I nstal l di stri butor cap. Ti ghten mounti ng
screws.
(5) 5.2L/5.9L Engi nes: I nstal l ai r cl eaner tube to
throttl e body.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
For removal and i nstal l ati on, refer to Mani fol d
Absol ute Pressure Sensor i n group 14, Fuel Systems.
ENGINE COOLANT TEMPERATURE SENSOR
For an operati onal descri pti on, di agnosi s and
removal /i nstal l ati on procedures, refer to Group 14,
Fuel System.
THROTTLE POSITION SENSOR
For an operati onal descri pti on, di agnosi s and
removal /i nstal l ati on procedures, refer to Group 14,
Fuel System.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
For an operati onal descri pti on, di agnosi s and
removal /i nstal l ati on procedures, refer to Group 14,
Fuel System.
DISTRIBUTOR5. 2L/5. 9L ENGINES
REMOVAL
CAUTION: Base ignition timing is not adjustable
on any 5.2L/5.9L V-8 engine. Distributors do not
have built in centrifugal or vacuum assisted
advance. Base ignition timing and timing advance
are controlled by the Powertrain Control Module
(PCM). Because a conventional timing light can not
be used to adjust distributor position after installa-
tion, note position of distributor before removal.
(1) Di sconnect negati ve cabl e from battery.
(2) Remove ai r cl eaner tube at throttl e body.
(3) Di sconnect coi l secondary cabl e at di stri butor
cap.
(4) Di sconnect al l secondary spark pl ug cabl es at
di stri butor cap. Note and mark posi ti on before
removal .
(5) Remove di stri butor cap from di stri butor (two
screws).
(6) Mark posi ti on of di stri butor housi ng i n rel a-
ti onshi p to engi ne or dash panel . Thi s i s done to ai d
i n i nstal l ati on.
(7) Before di stri butor i s removed, number one cyl -
i nder must be brought to Top Dead Center (TDC) fi r-
i ng posi ti on.
(8) Attach a socket to Crankshaft Vi brati on
Damper mounti ng bol t.
(9) Sl owl y rotate engi ne cl ockwi se, as vi ewed from
front, unti l i ndi cati ng mark on crankshaft vi brati on
damper i s al i gned to 0 degree (TDC) mark on ti mi ng
chai n cover (Fi g. 33).
(10) The di stri butor rotor shoul d now be al i gned to
CYL. NO. 1 al i gnment mark (stamped) i nto camshaft
posi ti on sensor (Fi g. 34). I f not, rotate crankshaft
through another compl ete 360 degree turn. Note posi -
ti on of number one cyl i nder spark pl ug cabl e (on the
cap) i n rel ati on to rotor. Rotor shoul d now be al i gned
to thi s posi ti on.
Fig. 32 Camshaft Position SensorTypical
(5.2L/5.9L Shown)
8D - 16 IGNITION SYSTEM ZJ
REMOVAL AND INSTALLATION (Continued)
(11) Di sconnect camshaft posi ti on sensor wi ri ng
harness 3way connector from mai n engi ne wi ri ng
harness.
(12) Remove di stri butor rotor from di stri butor
shaft.
(13) Remove di stri butor hol ddown cl amp bol t and
cl amp (Fi g. 35).
(14) Remove di stri butor from vehi cl e.
CAUTION: Do not crank engine with distributor
removed. Distributor/crankshaft relationship will be
lost.
INSTALLATION
I f engi ne has been cranked whi l e di stri butor i s
removed, establ i sh rel ati onshi p between di stri butor
shaft and number one pi ston posi ti on as fol l ows:
Rotate crankshaft i n a cl ockwi se di recti on, as
vi ewed from front, unti l number one cyl i nder pi ston
i s at top of compressi on stroke (compressi on shoul d
be fel t on fi nger wi th number one spark pl ug
removed). Then conti nue to sl owl y rotate engi ne
cl ockwi se unti l i ndi cati ng mark (Fi g. 33) i s al i gned to
0 degree (TDC) mark on ti mi ng chai n cover.
(1) Cl ean top of cyl i nder bl ock for a good seal
between di stri butor base and bl ock.
(2) Li ghtl y oi l the rubber o-ri ng seal on di stri butor
housi ng.
(3) I nstal l rotor to di stri butor shaft.
(4) Posi ti on di stri butor i nto engi ne to i ts ori gi nal
posi ti on. Engage tongue of di stri butor shaft wi th sl ot
i n di stri butor oi l pump dri ve gear. Posi ti on rotor to
number one spark pl ug cabl e posi ti on.
(5) I nstal l di stri butor hol ddown cl amp and cl amp
bol t. Do not ti ghten bol t at thi s ti me.
(6) Rotate di stri butor housi ng unti l rotor i s al i gned
to CYL. NO. 1 al i gnment mark on camshaft posi ti on
sensor (Fi g. 34).
(7) Ti ghten cl amp hol ddown bol t (Fi g. 35) to 22.5
Nm (200 i n. l bs.) torque.
(8) Connect camshaft posi ti on sensor wi ri ng har-
ness to mai n engi ne harness.
(9) I nstal l di stri butor cap. Ti ghten mounti ng
screws.
(10) I nstal l secondary cabl es to di stri butor cap.
(11) Refer to fol l owi ng, Checki ng Di stri butor Posi -
ti on.
CHECKING DISTRIBUTOR POSITION
To veri fy correct di stri butor rotati onal posi ti on, the
DRB scan tool must be used.
WARNING: WHEN PERFORMING THE FOLLOWING
TEST, THE ENGINE WILL BE RUNNING. BE CARE-
FUL NOT TO STAND IN LINE WITH THE FAN
BLADES OR FAN BELT. DO NOT WEAR LOOSE
CLOTHING.
Fig. 33 Damper-To-Cover Alignment MarksTypical
Fig. 34 Rotor Alignment Mark5.2L/5.9L Engines
Fig. 35 Distributor Holddown Clamp5.2L/5.9L
Engines
ZJ IGNITION SYSTEM 8D - 17
REMOVAL AND INSTALLATION (Continued)
(1) Connect DRB scan tool to data l i nk connector.
The data l i nk connector i s l ocated i n passenger com-
partment, bel ow and to l eft of steeri ng col umn.
(2) Gai n access to SET SYNC screen on DRB.
(3) Fol l ow di recti ons on DRB screen and start
engi ne. Bri ng to operati ng temperature (engi ne must
be i n cl osed l oop mode).
(4) Wi th engi ne runni ng at idle speed, the words
I N RANGE shoul d appear on screen al ong wi th 0.
Thi s i ndi cates correct di stri butor posi ti on.
(5) I f a pl us (+) or a mi nus (-) i s di spl ayed next to
degree number, and/or the degree di spl ayed i s not
zero, l oosen but do not remove di stri butor hol ddown
cl amp bol t. Rotate di stri butor unti l I N RANGE
appears on screen. Conti nue to rotate di stri butor
unti l achi evi ng as cl ose to 0 as possi bl e. After
adjustment, ti ghten cl amp bol t to 22.5 Nm (200 i n.
l bs.) torque.
The degree scal e on SET SYNC screen of DRB i s
referri ng to fuel synchroni zati on onl y. It is not
referring to ignition timing. Because of thi s, do
not attempt to adjust i gni ti on ti mi ng usi ng thi s
method. Rotati ng di stri butor wi l l have no effect on
i gni ti on ti mi ng. Al l i gni ti on ti mi ng val ues are con-
trol l ed by powertrai n control modul e (PCM).
(6) After testi ng, i nstal l ai r cl eaner tube to throttl e
body.
DISTRIBUTOR4. 0L ENGINE
Al l 4.0L di stri butors contai n an i nternal oi l seal
that prevents oi l from enteri ng the di stri butor hous-
i ng. The seal i s not servi ceabl e.
Factory repl acement di stri butors are equi pped wi th
a pl asti c al i gnment pi n al ready i nstal l ed. The pi n i s
l ocated i n an access hol e on the bottom of the di stri b-
utor housi ng (Fi g. 36). I t i s used to temporari l y l ock
the rotor to the cyl i nder number 1 posi ti on duri ng
i nstal l ati on. The pi n must be removed after i nstal l -
i ng the di stri butor.
The camshaft posi ti on sensor i s l ocated i n the di s-
tri butor on al l 4.0L engi nes (Fi g. 37). For removal /i n-
stal l ati on procedures, refer to Camshaft Posi ti on
Sensor. Di stri butor removal i s not necessary for sen-
sor removal .
Refer to (Fi g. 37) for an expl oded vi ew of di stri bu-
tor.
A fork wi th a sl ot i s suppl i ed on bottom of di stri b-
utor housi ng where the housi ng base seats agai nst
engi ne bl ock (Fi g. 37). The centerl i ne of the sl ot
al i gns wi th di stri butor hol ddown bol t hol e i n engi ne
bl ock. Because of the fork, the di stri butor cannot be
rotated. Di stri butor rotati on i s not necessary as al l
i gni ti on ti mi ng requi rements are handl ed by the
powertrai n control modul e (PCM).
The posi ti on of di stri butor determi nes fuel synchro-
ni zati on onl y. I t does not determi ne i gni ti on ti mi ng.
NOTE: Do not attempt to modify this fork to attain
ignition timing.
REMOVAL4.0L ENGINE
(1) Di sconnect negati ve battery cabl e at battery.
(2) Di sconnect coi l secondary cabl e at coi l .
(3) Remove di stri butor cap from di stri butor (2
screws). Do not remove cabl es from cap. Do not
remove rotor.
Fig. 36 Plastic Alignment Pin4.0L Engine
Fig. 37 Distributor 4.0L EngineTypical
8D - 18 IGNITION SYSTEM ZJ
REMOVAL AND INSTALLATION (Continued)
(4) Di sconnect di stri butor wi ri ng harness 3way
connector from mai n engi ne harness.
(5) Remove cyl i nder number 1 spark pl ug.
(6) Hol d a fi nger over the open spark pl ug hol e.
Rotate engi ne at vi brati on dampener bol t unti l com-
pressi on (pressure) i s fel t.
(7) Sl owl y conti nue to rotate engi ne. Do thi s unti l
ti mi ng i ndex mark on vi brati on damper pul l ey al i gns
wi th top dead center (TDC) mark (0 degree) on ti m-
i ng degree scal e (Fi g. 38). Al ways rotate engi ne i n
di recti on of normal rotati on. Do not rotate engi ne
backward to al i gn ti mi ng marks.
(8) Remove di stri butor hol ddown bol t and cl amp.
(9) Remove di stri butor from engi ne by sl owl y l i ft-
i ng strai ght up.
(10) Note that rotor wi l l rotate sl i ghtl y i n a coun-
tercl ockwi se di recti on whi l e l i fti ng up the di stri butor.
The oi l pump gear wi l l al so rotate sl i ghtl y i n a coun-
tercl ockwi se di recti on whi l e l i fti ng up the di stri butor.
Thi s i s due to the hel i cal cut gears on di stri butor and
camshaft.
(11) Note removed posi ti on of rotor duri ng di stri b-
utor removal . Duri ng i nstal l ati on, thi s wi l l be
referred to as the Pre-posi ti on.
(12) Observe sl ot i n oi l pump gear through hol e on
si de of engi ne. I t shoul d be sl i ghtl y before (counter-
cl ockwi se of) the 11 ocl ock posi ti on (Fi g. 39).
(13) Remove and di scard ol d di stri butor-to-engi ne
bl ock gasket.
INSTALLATION
(1) I f engi ne crankshaft has been rotated after di s-
tri butor removal , cyl i nder number 1 must be
returned to i ts proper fi ri ng stroke. Refer to previ ous
REMOVAL Step 5 and Step 6. These steps must be
done before i nstal l i ng di stri butor.
(2) Check posi ti on of sl ot on oi l pump gear. I t
shoul d be just sl i ghtl y before (countercl ockwi se of)
the 11 ocl ock posi ti on (Fi g. 39). I f not, pl ace a fl at
bl ade screwdri ver i nto oi l pump gear and rotate i t
i nto proper posi ti on.
(3) Factory repl acement di stri butors are equi pped
wi th a pl asti c al i gnment pi n al ready i nstal l ed (Fi g.
36). Thi s pi n i s used to temporari l y hol d rotor to cyl -
i nder number 1 fi ri ng posi ti on duri ng di stri butor
i nstal l ati on. I f pi n i s i n pl ace, proceed to Step 8. I f
not, proceed to next step.
(4) I f ori gi nal di stri butor i s to be rei nstal l ed, such
as duri ng engi ne overhaul , the pl asti c pi n wi l l not be
avai l abl e. A 3/16 i nch dri ft pi n punch tool may be
substi tuted for pl asti c pi n.
(5) Remove camshaft posi ti on sensor from di stri b-
utor housi ng. Li ft strai ght up.
Fig. 38 Align Timing Marks4.0L Engine
Fig. 39 Slot At 11 Oclock Position4.0L Engine
ZJ IGNITION SYSTEM 8D - 19
REMOVAL AND INSTALLATION (Continued)
(6) Four di fferent al i gnment hol es are provi ded on
the pl asti c ri ng (Fi g. 40). Note that 2.5L and 4.0L
engines have different alignment holes (Fig. 40).
(7) Rotate di stri butor shaft and i nstal l pi n punch
tool through proper al i gnment hol e i n pl asti c ri ng
(Fi g. 40) and i nto mati ng access hol e i n di stri butor
housi ng. Thi s wi l l prevent di stri butor shaft and rotor
from rotati ng.
(8) Cl ean di stri butor mounti ng hol e area of engi ne
bl ock.
(9) I nstal l new di stri butor-to-engi ne bl ock gasket
(Fi g. 37).
(10) I nstal l rotor to di stri butor shaft.
Pre-posi ti on di stri butor i nto engi ne whi l e hol di ng
centerl i ne of base sl ot i n 1 ocl ock posi ti on (Fi g. 41).
Conti nue to engage di stri butor i nto engi ne. The rotor
and di stri butor wi l l rotate cl ockwi se duri ng i nstal l a-
ti on. Thi s i s due to the hel i cal cut gears on di stri bu-
tor and camshaft. When di stri butor i s ful l y seated to
engi ne bl ock, the centerl i ne of base sl ot shoul d be
al i gned to cl amp bol t mounti ng hol e on engi ne (Fi g.
42). The rotor shoul d al so be poi nted at 5 ocl ock
posi ti on.
I t may be necessary to rotate rotor and di stri butor
shaft (very sl i ghtl y) to engage di stri butor shaft wi th
sl ot i n oi l pump gear. The same may have to be done
to engage di stri butor gear wi th camshaft gear.
The distributor is correctly installed when:
rotor i s poi nted at 5 ocl ock posi ti on.
pl asti c al i gnment pi n (or pi n punch tool ) i s sti l l
i nstal l ed to di stri butor.
number 1 cyl i nder pi ston i s set at top dead cen-
ter (TDC) (compressi on stroke).
centerl i ne of the sl ot at base of di stri butor i s
al i gned to centerl i ne of di stri butor hol ddown bol t
hol e on engi ne. I n thi s posi ti on, the hol ddown bol t
shoul d easi l y pass through sl ot and i nto engi ne.
No adjustments are necessary. Proceed to next step.
(11) I nstal l di stri butor hol ddown cl amp and bol t.
Ti ghten bol t to 23 Nm (17 ft. l bs.) torque.
(12) Remove pi n punch tool from di stri butor. Or, i f
pl asti c al i gnment pi n was used, remove i t strai ght
down from bottom of di stri butor. Di scard pl asti c pi n.
Fig. 40 Pin Alignment Holes4.0L Engine
Fig. 41 Distributor Pre-position4.0L Engines
Fig. 42 Distributor Engaged Position4.0L Engine
8D - 20 IGNITION SYSTEM ZJ
REMOVAL AND INSTALLATION (Continued)
(13) I f removed, i nstal l camshaft posi ti on sensor to
di stri butor. Al i gn wi ri ng harness grommet to notch i n
di stri butor housi ng.
(14) I nstal l rotor.
CAUTION: If distributor cap is incorrectly posi-
tioned on distributor housing, the cap or rotor may
be damaged when engine is started.
(15) I nstal l di stri butor cap. Ti ghten di stri butor cap
hol ddown screws to 3 Nm (26 i n. l bs.) torque.
(16) I f removed, i nstal l spark pl ug cabl es to di s-
tri butor cap. For proper fi ri ng order, refer to Speci fi -
cati ons secti on at end of thi s group. See Engi ne
Fi ri ng Order.
(17) Connect di stri butor wi ri ng harness to mai n
engi ne harness.
(18) Connect battery cabl e to battery.
POWERTRAIN CONTROL MODULE (PCM)
Refer to Group 14, Fuel System for procedures.
IGNITION SWITCH AND KEY CYLINDER
The i gni ti on key must be i n the key cyl i nder for
cyl i nder removal .
KEY CYLINDER REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) I f equi pped wi th ti l t col umn, remove ti l t l ever
by turni ng i t countercl ockwi se.
(3) Remove upper and l ower covers (shrouds) from
steeri ng col umn (Fi g. 43).
(4) I f equi pped wi th automati c transmi ssi on, pl ace
shi fter i n PARK posi ti on.
(5) A retai ni ng pi n (Fi g. 44) i s l ocated at si de of
key cyl i nder assembl y.
(a) Rotate key to RUN posi ti on.
(b) Press i n on retai ni ng pi n whi l e pul l i ng key
cyl i nder from i gni ti on swi tch.
IGNITION SWITCH REMOVAL
(1) Remove key l ock cyl i nder. Refer to previ ous
steps.
(2) Remove 3 i gni ti on swi tch mounti ng screws
(Fi g. 45). Use tamper proof torx bi t (Snap-On
SDMTR10 or equi val ent) to remove screws.
(3) Gentl y pul l swi tch away from col umn. Rel ease
connector l ocks on 7-termi nal wi ri ng connector at
i gni ti on swi tch and remove connector (Fi g. 46).
(4) Rel ease connector l ock on 4-termi nal hal o l amp
wi ri ng connector and remove connector (Fi g. 46).
Fig. 43 Shroud Removal/InstallationTypical
Fig. 44 Retaining Pin
Fig. 45 Switch Mounting Screws
ZJ IGNITION SYSTEM 8D - 21
REMOVAL AND INSTALLATION (Continued)
IGNITION SWITCH AND KEY CYLINDER
INSTALLATION
I f i nstal l i ng ignition key lock cylinder only,
proceed to fol l owi ng steps 2, 3 and 4. Al so refer to fol -
l owi ng steps 12 through 18. I f i nstal l i ng both swi tch
and key cyl i nder, refer to steps 1 through 18.
(1) Rotate fl ag (Fi g. 47) on rear of i gni ti on swi tch
unti l i n RUN posi ti on. Thi s step must be done to
al l ow tang (Fi g. 48) on key cyl i nder to fi t i nto sl ots
(Fi g. 45) wi thi n i gni ti on swi tch.
(2) Wi th key i nto i gni ti on key cyl i nder, rotate key
cl ockwi se unti l retai ni ng pi n can be depressed (Fi g.
48) or (Fi g. 49).
(3) I nstal l key cyl i nder i nto i gni ti on swi tch by
al i gni ng retai ni ng pi n i nto retai ni ng pi n sl ot (Fi g.
49). Push key cyl i nder i nto swi tch unti l retai ni ng pi n
engages. After pi n engages, rotate key to OFF or
LOCK posi ti on.
(4) Check for proper retenti on of key cyl i nder by
attempti ng to pul l cyl i nder from swi tch.
(5) Automati c Transmi ssi on Onl y: Before attachi ng
i gni ti on swi tch to steeri ng col umn, the transmi ssi on
shi fter must be i n PARK posi ti on. The park l ock
dowel pi n on rear of i gni ti on swi tch (Fi g. 50) must
al so be properl y i ndexed i nto the park l ock l i nkage
(Fi g. 51) before i nstal l i ng swi tch.
(6) The fl ag at rear of i gni ti on swi tch (Fi g. 50)
must be properl y i ndexed i nto steeri ng col umn before
i nstal l i ng swi tch. Thi s fl ag i s used to operate the
steeri ng wheel l ock l ever i n steeri ng col umn (Fi g. 52).
Thi s l ever al l ows steeri ng wheel posi ti on to be l ocked
when key swi tch i s i n LOCK posi ti on.
(7) Pl ace i gni ti on swi tch i n LOCK posi ti on. The
swi tch i s i n the LOCK posi ti on when col umn l ock
fl ag i s paral l el to i gni ti on swi tch termi nal s (Fi g. 50).
Fig. 46 Ignition Switch and Halo Lamp Connectors
Fig. 47 Flag in RUN Position
Fig. 48 Key CylinderRear View
Fig. 49 Installing Key Cylinder Into Switch
8D - 22 IGNITION SYSTEM ZJ
REMOVAL AND INSTALLATION (Continued)
(8) Automati c Transmi ssi on Onl y: Appl y a l i ght
coati ng of grease to park l ock dowel pi n and park
l ock sl i der l i nkage. Before i nstal l i ng swi tch, push the
park l ock sl i der l i nkage (Fi g. 51) forward unti l i t bot-
toms. Do a fi nal posi ti oni ng by pul l i ng i t rearward
about one-quarter i nch.
(9) Appl y a l i ght coati ng of grease to both col umn
l ock fl ag and shaft at end of fl ag.
(10) Pl ace i gni ti on swi tch i nto openi ngs on steeri ng
col umn.
(a) Automati c Transmi ssi on Onl y: Be sure park
l ock dowel pi n on rear of i gni ti on swi tch enters sl ot
i n park l ock sl i der l i nkage (Fi g. 51).
(b) Be sure fl ag on rear of swi tch i s posi ti oned
above steeri ng wheel l ock l ever (Fi g. 52).
(c) Al i gn dowel pi ns on rear of swi tch i nto hol es
on si de of steeri ng col umn.
(d) I nstal l 3 i gni ti on swi tch mounti ng screws.
Ti ghten screws to 3 Nm .5 Nm (26 i n. l bs. 4
i n. l bs.) torque.
(11) Connect el ectri cal connectors to i gni ti on
swi tch and hal o l amp. Make sure that swi tch l ocki ng
tabs are ful l y seated i n wi ri ng connectors.
(12) I nstal l steeri ng col umn covers (shrouds).
Ti ghten screws to 2 Nm (17 i n. l bs.) torque.
(13) I nstal l ti l t col umn l ever (i f equi pped).
(14) Connect negati ve cabl e to battery.
(15) Check for proper operati on of hal o l i ght.
(16) Automati c Transmi ssi on Onl y: Shi fter shoul d
l ock i n PARK posi ti on when key i s i n LOCK posi ti on
(i f equi pped wi th shi ft l ock devi ce). Shi fter shoul d
unl ock when key rotated to ON posi ti on.
(17) Check for proper operati on of i gni ti on swi tch
i n ACCESSORY, LOCK, OFF, ON, RUN, and START
posi ti ons.
(18) Steeri ng wheel shoul d l ock when key i s i n LOCK
posi ti on. Rotate steeri ng wheel to veri fy. Steeri ng wheel
shoul d unl ock when key i s rotated to ON posi ti on.
SHIFTER/IGNITION INTERLOCK
On model s equi pped wi th an automati c transmi s-
si on, a cabl e connects the i gni ti on swi tch wi th the
fl oor shi ft l ever. The shi fter wi l l be l ocked i n the
PARK posi ti on when the i gni ti on key i s i n the LOCK
or ACCESSORY posi ti ons. The cabl e can be adjusted
or repl aced. Refer to Group 21, Transmi ssi ons for
procedures. The i gni ti on i nterl ock devi ce wi thi n the
steeri ng col umn i s not servi ceabl e. I f servi ce i s nec-
essary, the steeri ng col umn must be repl aced. Refer
to Group 19, Steeri ng for procedures.
Fig. 50 Ignition Switch View From Column
Fig. 51 Park Lock LinkageAutomatic
TransmissionTypical
Fig. 52 Steering Wheel Lock Lever
ZJ IGNITION SYSTEM 8D - 23
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
VECI LABEL
I f anythi ng di ffers between the speci fi cati ons found
on the Vehi cl e Emi ssi on Control I nformati on (VECI )
l abel and the fol l owi ng speci fi cati ons, use speci fi ca-
ti ons on VECI l abel . The VECI l abel i s l ocated i n the
engi ne compartment.
IGNITION TIMING
I gni ti on ti mi ng i s not adjustabl e on any engi ne. Refer
to I gni ti on Ti mi ng i n the Di agnosti cs/Servi ce Procedures
secti on of thi s group for more i nformati on.
ENGINE FIRING ORDER4. 0L 6-CYLINDER
ENGINE
ENGINE FIRING ORDER5. 2L/5. 9L V-8 ENGINES
8D - 24 IGNITION SYSTEM ZJ
TORQUE CHART
DESCRIPTION TORQUE
Crankshaft Posi ti on Sensor
4.0L Engi ne . . . . . . . . . . . . . . . .7 Nm (60 i n. l bs.)
Crankshaft Posi ti on Sensor
5.2L/5.9L Engi ne . . . . . . . . . . . .8 Nm (70 i n. l bs.)
Di stri butor Hol d Down Bol t
Al l Engi nes . . . . . . . . . . . . . . . .23 Nm (17 ft. l bs.)
I gni ti on Coi l Mounti ng
(i f tapped bol ts are used) . . . . . .5 Nm (50 i n. l bs.)
I gni ti on Coi l Mounti ng
(i f nuts/bol ts are used) . . . . . .11 Nm (100 i n. l bs.)
Powertrai n Control Modul e
(PCM) Mounti ng Screws . . . . . . .1 Nm (9 i n. l bs.)
Spark Pl ugsAl l Engi nes. . . . . . .41 Nm (30 ft. l bs.)
SPARK PLUGS
SPARK PLUG CABLE RESISTANCE
IGNITION COIL RESISTANCE
ENGINE PLUG TYPE ELECTRODE GAP
4.0L 6-CYL. RC12LYC 0.89 mm (.035 in.)
5.2/5.9L V-8 RC12LC4 1.01 mm (.040 in.)
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
COIL MANUFACTURER
PRIMARY RESISTANCE 21-27C
(70-80F)
SECONDARY RESISTANCE
21-27C (70-80F)
Diamond 0.97 - 1.18 Ohms 11,300 - 15,300 Ohms
Toyodenso 0.95 - 1.20 Ohms 11,300 - 13,300 Ohms
ZJ IGNITION SYSTEM 8D - 25
SPECIFICATIONS (Continued)